In preparation for casting, I sprayed the mold with Ease Release, and began measuring out Rebound 25.
I did 3 applications: the first two being a few hours apart...
… with the last one (thickened with Thi-Vex) a day later. I did the registration keys again in the form of a cross, however later found them to cause a problem.
Silicone is a rubber that stretches and compresses quite easily. When you have profound details like the cross in the above photo, and then apply Plasti-Paste to it to create a mother mold the paste captures that detailing to precise dimensions.
NOTE: I went with the original Plasti-Paste this time. The main difference between the original and Plasti-Paste II is that II takes paint, while the original does not. Since this doesn't matter to me, I went with the former to save costs ($30 cheaper per gallon kit).
What this means is that you will never be able to fit the rubber skin back into the mother mold 100% snug. Therefore, any imperfection in the fit will result in warping!! I wasted a pull doing this before cutting the cross off the silicone mold.
Anyway, the detailing of the mask was captured beautifully by the silicone!
So, I prepped it in the usual way by applying mold release and some baby powder (though powder coating turned out to be unnecessary because the thing would have to be sanded anyway), mixed up some SC 65D, and cast the mask.
After some trimming and sanding, this is what I ended up with!
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- Third Silicone Mold and Cast